Food forming concept

ABSTRACT

The present invention relates to a food forming drum comprising a multitude of rows product cavities, each row comprising a multitude of product cavities, wherein the product cavities are provided as one or more at least partially porous members made from a porous material with interconnecting pores. The present invention further relates to a food forming apparatus comprising a food forming drum and a porous member. Additionally, the present invention relates to a movable unit to transport a drum and a method to change a drum or clean the food forming apparatus.

FIELD

The present invention relates to a food forming drum comprising amultitude of rows product cavities, each row comprising a multitude ofproduct cavities, wherein the product cavities are provided as one ormore at least partially porous members made from a porous material withinterconnecting pores. The present invention further relates to a foodforming apparatus comprising a food forming drum and a porous member.Additionally, the present invention relates to a movable unit totransport a drum and a method to change a drum or clean the food formingapparatus.

BACKGROUND

Food forming drums are utilized in machines, which form food products,like patties from a food mass. Such an apparatus is for exampledescribed in the U.S. Pat. No. 3,205,837. However the food forming drumdescribed in this patent application is difficult to produce and hashygienic problems.

It was therefore the objective of the present invention to provide afood forming drum, which does not have the deficiencies of the devicesaccording of the state of the art.

This problem is attained by a food forming drum comprising a multitudeof rows product cavities, each row comprising one or a multitude ofproduct cavities, wherein the product cavities are provided as one ormore at least partially porous members made from a porous material withinterconnecting pores.

SUMMARY

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

The present invention relates to a food forming drum, which is part of afood forming apparatus. This food forming drum has at its outer surfacea multitude of product cavities, which are open towards thecircumference of the drum and in which the food mass is formed into afood product, for example a patty. This food forming drum comprises,according to the present invention, a multitude of rows of productcavities, whereas each row comprises one or a multitude of productcavities, side by side. The rows are arranged in parallel to the middleaxis of the inventive drum. During production, the drum turns and in oneposition the product cavities in one row are filled with the food massand in a downstream position, the formed food mass is discharged fromthe product cavities, located in one row. Subsequently, the productcavities in one row of cavities can be filled again and so on. In orderto vent the product cavities during their filling and/or in order tosupport the discharge of the product, the product cavities are at leastpartially made of a porous material, for example sintered metal, whichis gas-permeable and via which the product cavity can be vented orthrough which gas, for example air, can be discharged, to loosen theformed product from the surface of the product cavity. Preferably, theporous material comprises pores/channels, which are interconnected toeach other.

The food forming drum further preferably comprises fluid channels, whichextend in the longitudinal direction of the drum, i.e. parallel to thecenter axis of the drum and extend preferably from one end to the otherend of the drum. Via each fluid channel, ventilation air can bedischarged, for example to the ambient, and/or compressed gas can beforced into the cavities to discharge the formed product. Additionally,a cleaning fluid can be forced through the channels and/or the porousmaterial of the product cavities.

The at least partially porous product cavities are provided as one ormore porous members, wherein the cavities are recesses in the porousmaterial. The porous members are preferably a cylinder or cylindersegments. The porous member(s) can extend entirely around an inner drumor can be inserts, which are inserted and then fixed to a preferablydrum-like structure. Each segment may comprise one or more rows ofcavities.

The porous member is part of a mould drum, which will be used formoulding products, e.g. patties, from a mass of food material, forexample meat, which mass will be delivered by a mass supply system. Thedrum comprises one or more rows with one or more cavities where aproduct cavity wall having at least partially a porous structure. Amovable unit will be used to loading/unloading the mould drum easilyfrom the forming apparatus and/or a cleaning apparatus and/or a storageunit and to move the mould drum between the forming apparatus and/orcleaning apparatus and/or a storage unit.

According to a preferred or inventive embodiment of the presentinvention, the member is directly or indirectly connected to an innercylinder at least one bonding location, wherein the pores at the surfaceof the porous member in the bonding location are at least partiallyclosed.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

By closing the pores of the porous material at the bonding location, itis assured, that the bonding material, for example glue or a brazingsolder will not penetrate into the porous material.

Preferably, each porous member is provided as an insert, with will be atleast partially inserted into a recess of a drum like inner member andbonded to this member. This bonding is preferably done by brazing orsoldering. Alternatively or additionally, each insert can be connectedto the drum by a form-, force and/or a friction-connection between theinsert and the drum and/or an inner member of the drum.

According to another inventive or preferred embodiment of the presentinvention, the pores at the surface of the porous member adjacent to afront end of the drum are at least partially closed.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

After the bonding of the porous members to the inner member, theresulting drum assembly will be preferably further machined.Particularly, the outer diameter of the drum assembly will be machinedto its final diameter and/or, the pores at the outer circumference ofthe drum will be closed and/or should be kept closed. With this step,for example grinding, or with an additional machining step the drumobtains its final diameter.

The pores can be closed for example by grinding with a suitable grindingwheel and suitable grinding parameters and/or it is preferably done bydeep rolling. During deep rolling, a rolling element, for example a ballbut preferably a roller, is pressed against the porous surface to beclosed or in case of a drum assembly, against the outer surface of thedrum. The compression created by the roller creates stress in thecontact area whereby this area will exceed the yield point and a plasticdeformation takes place in the surface layer of the mould drum. Thepores of the porous inserts will be closed by this action. An additionaladvantage is that the increased density in the surface layer willincrease the strength and wear resistance in this layer. The drum cannow be stored. Once there is an order for a drum, the desired productcavities can be machined.

Additionally or alternatively, the pores of the porous member are atleast partially closed by shot-peening. Shot peening is a cold workingprocess used to close the pores at the surface of the porous materialand/or to produce a residual layer. It entails impacting a surface withshot (round metallic, glass, or ceramic particles) with force sufficientto create plastic deformation. It is similar to sandblasting, exceptthat it operates by the mechanism of plasticity rather than abrasion:each particle functions as a ball-peen hammer that closes the pores.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

According to another preferred or inventive embodiment of the presentinvention, the mould drum comprises an inner cylinder and at least oneporous member and at least one rib between the cylinder and the porousmember, wherein the rib is connected to the cylinder by a form- and/orforce-fit or by an adhesive bond.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

Preferably, the ribs are connected to the porous member and/or the innercylinder by brazing.

Each rib can utilized to provide a certain distance between the porousmember and an inner cylinder, to support the porous member, to provide achannel and/or to at least partially block fluid flow through the porousmaterial.

According to another preferred or inventive embodiment of the presentinvention, the porous member comprises a recess, which partiallyaccommodates a rib and that the rib preferably reduces the fluidexchange between two rows of product cavities.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

Another preferred or inventive embodiment of the present invention is afood forming drum comprising an inner cylinder and at least one porousmember and at least one rib between the cylinder and the porous segment,wherein in the rib a fluid channel is provided.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

The fluid channel in the rib is preferably open towards the porousmaterial. The cross section of the fluid channel is, for example, U- orV-shaped. This channel can be for example connected to a pressure mediumor to a vacuum source. Due to the vacuum, air that tries to flow fromone row of cavities to the next can be at least reduced.

According to a preferred or inventive embodiment of the presentinvention, the food forming drum, comprises a multitude of rows ofpreferably porous product cavities, the drum further comprising at leasttwo form-fit-means to rotate the drum, wherein the form-fit-means canhave a different shape.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

The form-fit-means which are part of the drum cooperate withcorresponding form fit means associated with rotational means, forexample a motor and/or a gear box. The form-fit-means transfer themoment of momentum from the rotational means to the drum. Since theform-fit-means at the drum and thus the form-fit-means at the rotationalmeans comprise at least two form-fit-means which are different, the drumcan only be connected to the rotational means of the food formingapparatus. Thus, the rotational position of the drum relative to therotational position of the rotational means is fixed and known by acontrol system of the inventive apparatus.

Another preferred or inventive embodiment of the present invention is afood forming drum comprising a multitude of rows product cavities, eachrow comprising one or a multitude of product cavities, wherein theproduct cavities are provided as one or more at least partially porousmembers made from a porous material with interconnecting pores, whereinthe member is directly or indirectly connected to an inner member atleast one connecting region, wherein the connection is made by anadhesive connection and/or by form- and/or force- and/orfriction-fit-means.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

According to this subject matter of the present invention, the porousmember is directly or indirectly connected to an inner member, forexample ribs at the inner cylinder. This connection can be adhesiveconnection and/or by form- and/or force- and/or friction-fit-means.Particularly the combination of an adhesive connection, for example bysoldering and/or brazing together with a form- and/or force- and/orfriction-connection is preferred.

The form- and/or force- and/or friction-means can be made from metaland/or a plastic material. The material of the form- and/or force-and/or friction-means can be inserted between the porous member and thedrum or a rib at the drum as a liquid, which subsequently solidifies.

The inner member is preferably a cylinder, preferably a cylinder withindentations and/or ribs to which the porous members are connected

Possible form- and/or force- and/or friction-connections between theporous member and the inner member are disclosed in WO 2012 107 236,particularly FIG. 13 and the corresponding description. The disclosureof this patent application is enclosed herewith by reference and thuspart of the disclosure of the present patent application.

Each porous member can be fixed to the inner member by one or moreseparate form- and/or force- and/or friction-means or one form- and/orforce- and/or friction-means can fix a multitude of porous members tothe inner member. Preferably one form- and/or force- and/orfriction-fit-means extends through a multitude of porous members, morepreferably through the entire axial length of the inner member.

Preferably, the form- and/or force- and/or friction-fit-means create apre-tension between the porous member and the form- and/or force- and/orfriction-fit-means and/or the inner member. This can be, for example,achieved by providing a form- and/or force- and/or friction-means with alarger diameter than the diameter of an opening in the dinner memberand/or the porous material. The form- and/or force- and/orfriction-means is pressed into this opening and thereby pretensions theporous member against the inner member.

Preferably, each porous member is fixed by two form- and/or force-and/or friction-fit-means at the inner member.

According to another inventive or preferred concept of the presentinvention, the food forming drum comprises a multitude of rows ofpreferably porous product cavities, which is bared rotationally at aforming apparatus, wherein the drum comprises at least at one of itsfront ends a truncated cone.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

After the food forming drum has been placed into a food formingapparatus, this cone preferably, at least partially form fits with acone that is provided at the food forming apparatus, preferably at theside of the food forming apparatus which provides the torque to rotatethe food forming drum.

Another preferred or inventive embodiment of the present invention istherefore a food forming apparatus with a seal member, preferably aflexible plate and a food forming drum, which comprises a truncated coneat its drive- and/or support side for the food forming drum.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

The truncated cone at the food forming drum and/or at the food formingapparatus can be utilized to center, fix, preferably clamp and/or securethe food forming drum at the food forming apparatus.

Another preferred or inventive embodiment of the present invention is afood forming drum comprising a porous member (78) with a multitude ofrows of porous product cavities, each row comprising a multitude ofporous product cavities, and wherein a gas is utilized to flush thecavities and/or remove formed products from the cavity and/or wherein afluid is utilized to clean the cavities, wherein the porous memberdesigned to allow a gas- and/or fluid exchange through the porous memberbetween two rows and/or between two passages.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

Due to this fluid flow, a gas exchange between two rows of cavities ispossible. Additionally or alternatively, a cleaning fluid can flowthrough the porous material from one cavity row to another.

Another preferred or inventive embodiment of the present invention is afood forming drum comprising a porous member with a multitude of rows ofporous product cavities, each row comprising a multitude of porousproduct cavities, and further comprising a source of reduced pressure,characterized in that this source of reduced pressure is connected tothe porous member in an area between two rows, to reduce gas exchangebetween two adjacent rows for example during the discharge of formedproducts.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

Preferably, the formed products are removed from the mould cavities byejecting a gas, preferably air through the bottom and/or the sidewall ofthe cavity. In order to avoid that during this ejection air passesunintentionally to adjacent rows, a negative pressure can be applied toan area or a volume between two adjacent rows of cavities.

Another preferred or inventive embodiment of the present invention is afood forming apparatus comprising a food forming drum and a flexibleplate, which abuts on the circumferential surface of the drum, whereinthe drum and/or the flexible plate comprise identification means andthat, based on the identification, the operational parameters of theapparatus are automatically set and/or that it is checked, whether theflexible plate and the drum fit.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

The flexible plate abuts against the radial surface of the drum andextents around a manifold through which the cavities are filled with thefood mass and works as a seal for the food mass. The plate is pressedagainst the surface of the food forming drum. The plate is flexible, sothat is contact area with the surface of the drum is maximized.

According to this embodiment, the flexible plate and/or the food formingdrum comprises an identification, for example an RFID, a bar-code or thelike. This identification can be manually or automatically entered intoa control system of the food forming apparatus. Based on thisidentification, it can be checked whether the food forming drum fits tothe flexible plate, e.g., whether the length and/or is width of theflexible plate matches the food forming drum. If this is not the case,the food forming apparatus will not start and/or a warning will bedispatched.

Alternatively or additionally, operational parameters of the foodforming apparatus, e.g. the feeding pressure of the product, the speedof rotation of the drum, the amount of gas ejected out of each cavity toremove the product from the mould cavity, the pressure which ismaintained or set after the filling is completed and/or the rotationalposition at which the products are removed from the drum, areautomatically set. This reduces the effort of the workers at the machineand/or avoids mistakes and/or accidents during the operation of the foodforming apparatus.

Another preferred or inventive subject matter of the present inventionis a food forming drum comprising a porous member, wherein the porousmember comprises two layers with different porosity which are bondedtogether, wherein the layer at the surface of the food forming drum hasa lower porosity than the layer inside the outer layer.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

According to this embodiment of the present invention, the outside layerof the porous member has preferably a denser structure than the innerlayer and can be, for example, a foil, a rolled plate or a thin walledtube. This can be advantageous because it saves the process-step toclose the pores at the outer circumference of the porous member. It isalso possible that the layered structure of the porous member, forexample the porous drum, is made by providing different powders in themold which will after pressing and sintering result in a two layerstructure, wherein the outer layer is at least essentially closed, sothat no compressed air can exit through this layer. After the sinteringprocess the porous base will adhere to the outside layer. The porouscavities are produced by removing the outer layer and the inner layer atleast partially in the locations in which a cavity is desired.

In a preferred embodiment, the outside layer is provided in thecircumferential direction as at least partially at one or more of theend faces of the insert. The outside layer in both circumferential endfaces is advantageous for the bonding between inserts and/or other partsof the drum. The outside layer in the two axial end faces of the insertis advantageous to seal the insert in this location.

The outside layer can be for example foil, plate(s) or made by providingdifferent powder in the mold which will after pressing and sinteringresult in a closed structure. After the sintering process porous basewill adhere to the outside layers.

Another preferred or inventive subject matter of the present inventionis a food forming drum comprising an inner cylinder and at least oneporous member and at least one rib between the cylinder and the porousmember, wherein the rib is connected to the cylinder by a form- and/orforce-fit or by an adhesive bond, and wherein the rib is providedmovable relative to the cylinder.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

Due the movement and or the deformation of the rib between two poroussegments, the rib can follow the porous segment during its shrinkageafter or during the sintering process. Hence the connection,particularly the material bond between the rib and the porous materialwill not be damaged and/or overloaded. The movement of the rib relativeto the cylinder is preferably a rotation.

Preferably, the rib provided deformable. This can be achieved byproviding the rib in a relatively soft material with a relatively lowmodulus of elasticity and/or a relatively thin rib and/or constructionalmeans such as indentations notches or the like, which improve thedeformation of the rib in the desired direction.

According to an inventive or preferred embodiment of the presentinvention, each rib is provided as two parts.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

The two parts are preferably mirror-symmetrically and extend both overthe entire length of the drum. Both parts are preferably connected tothe cylinder. Preferably, a gap is provided between the two parts, whichpreferably extends in radial direction. During the shrinkage of theporous material this the size, particularly its width increases.Preferably, the gap is closed and/or filled, for example by welding,after the shrinkage is completed.

In a preferred embodiment the size of the gap is increased beyond thedegree of shrinkage so that the porous segment between two ribs iscompressed. This can be achieved for example by mechanical or thermalforces. Subsequently, this gap is filled with a material, for example awelding material, that fixes the gap in its desired shape so that theporous segments remain compressed.

Another preferred or inventive embodiment of the present invention is afood forming apparatus, wherein the food forming drum rotates on aspindle and wherein the spindle is designed to be removed preferablytogether with the drum.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

According to this embodiment of the present invention, the food formingdrum rotates around a spindle, which is connected to the inventive foodforming apparatus. In case the food forming drum has to be removed, forexample for a product change or for cleaning purposes, the drum isremoved together with the spindle. Prior to removing the spindle, it hasto be disconnected from the food forming apparatus.

The removal of the spindle together with the drum has the advantage,that the food forming apparatus can better be cleaned and that thespindle can be utilized to bear the drum on a transportation trolley.

Preferably, the spindle is part of a production support means, whichcomprises a support structure, bearings for the drum. This productionsupport means support the food forming drum on the food formingapparatus. More preferred, this entire production support means areremoved together with the drum.

Another preferred or inventive embodiment of the present invention is afood forming apparatus with a seal member, preferably a flexible plateand a food forming drum, which is beared with bearings on a spindle,wherein the seal member and the bearings are mechanically connected suchthat they build a force closed system.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

The seal member, e.g. a flexible plate abuts against the radial surfaceof the drum and extents around a manifold through which the cavities arefilled with the food mass and works as a seal for the food mass. Theplate is pressed against the surface of the food forming drum. The plateis flexible, so that is contact area with the surface of the drum ismaximized.

Due the closed force system, the force that as to be absorbed by theframe of the food forming apparatus is reduced and/or the contactbetween the seal member and the radial circumference of the drum is moreintimate.

Another preferred or inventive embodiment of the present invention is aporous member, which is part of a food forming drum, wherein itcomprises an embedded fluid channel and/or a support area parallel tothe centre axis of the drum.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

According to this embodiment of the present invention, the porousmaterial comprises an embedded fluid channel. This fluid channel is notthe pores of the porous material, but a channel, that preferably extendsparallel to the axis of rotation of the drum and connects the mouldcavities of one row of fluid cavities fluid-wise. Via such a channel agas can be supplied to the mould cavities of one row to eject theproducts from the mould cavities and/or the mould cavities can be ventedvia this channel during their filling. The channel is preferablymachined into the porous material or part of the form which is utilizedto produce the porous member.

Another preferred or inventive embodiment of the present invention is amovable unit to transport the drum, wherein it comprises a support framefor a production support means, the production support means comprisinga spindle and a support structure to bear the spindle.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

The movable unit is designed such that comprises a support frame towhich the entire production support means can be attached. Thisproduction support means preferably remains at the movable unit in casethe mould drum is stored in a storage and/or in case that the drum iscleaned in a cleaning unit.

Another subject matter of the present invention is a method to change afood forming drum at a food forming apparatus comprising a frame theproduction support structure of the food forming drum is connected,wherein the drum is changed together with the production support means.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

Another subject matter of the present invention is a method to clean afood forming apparatus comprising a spindle around which bears arotating food forming drum, wherein the spindle is removed prior tocleaning, preferably together with the drum.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

Another subject matter of the present invention is a method to operate afood forming apparatus, which comprises a mould drum with a multitude ofrows of mould cavities, whereby each row is connected to a passage whichcan be subjected to a medium with positive or negative pressure relativeto the ambient pressure, characterized in that at two adjacent passagesone passage is subjected to a medium with positive pressure and theadjacent passage to a medium with negative pressure.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa. With this embodiment, it is avoided that during discharge ofa product from a certain row of cavities, products in an adjacent roware removed from the product cavities unintentionally.

Another subject matter of the present invention is a method to produce afood forming drum, which comprises an inner cylinder and a porousmember, which is made from a sintered powder, wherein the powder isdirectly applied to the inner cylinder and/or to ribs which are part ofthe inner cylinder.

According to this embodiment of the present invention, the sintering ofthe porous material takes place in situ, i.e. at the inner member, forexample the inner cylinder of the drum. After pressing and sintering ofthe power, for example a metal powder, a porous structure remainswherein product cavities can be made and/or pores at the surface can beclosed.

The porous member can be a cylinder made of one or more pieces or can beinserts, each being placed between and/or above one or more rib(s).

The porous member is preferably made form a sintered material,preferably sintered metal.

Each rib can be provided as a single piece together with the innermember or each rib can be attached to the inner member for example by anadhesive connection.

Preferably the axis of rotation of the inner member is provided parallelto a vertically.

According to a preferred embodiment of the present invention, the porousmaterial comprises two or more layers. The two layers can be made fromthe same or a different material. However more preferably, the materialis different. Preferably the two layers differ in their porosity.Preferably, the two layers are provided coaxially.

Preferably, the two layers are produced sequentially. Firstly, the innerlayer is produced and then the outer layer. Afterwards, mould cavitiesare machined into both porous layers.

Another preferred or inventive subject matter of the present inventionis a method to produce a food forming drum, which comprises an innercylinder a multitude of ribs and a porous member made from a sinteredpowder and provided between two ribs respectively, wherein the ribs moverelative to the inner cylinder and/or deform during or after thesintering of the porous members, particularly due to a shrinkage-force.

Preferably a gap within the rib or between two ribs resulting from themovement and/or the deformation of the rib, particularly between tworibs or two parts of the rib is closed. This an be achieved for exampleby providing a filling material such as a welding material which morepreferably is machined afterwards.

Another subject matter of the present invention is a mould drum,comprising an inner member and a porous member, wherein the porousmember comprises two layers made from a powder material.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

The layers can be made from the same or different materials. The layerscan be treated identically or differently, for example heat- and/orpressure-treatment.

Preferably, the layers are provided at least partially coaxially,wherein the outer layer has less porosity than the inner layer. Morepreferably, the material of the outer layer is more compressed than thematerial of the inner layer.

According to yet another preferred or inventive embodiment, the porousmember is produced in situ at the inner member.

In situ according to the invention means, that the porous member, isproduced, preferably sintered, at the inner member, i.e. the innermember and the porous layer are not produced as separate parts and thenattached to each other. A disassembly of the porous member from theinner member is impossible without destroying the porous member.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

Preferably, each porous member comprises two layers, which are, morepreferably, both produced in situ.

Another subject matter of the present invention is a food forming drumresulting from this inventive process.

Another inventive or preferred subject matter of the present inventionis a system for moulding products from a mass of food materialcomprising the inventive food forming apparatus and/or the inventivemovable unit and/or the production support means and/or the drum and/orthe inventive cleaning apparatus and/or a storage unit.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

Another preferred or inventive subject matter of the present inventionis a food forming system comprising the inventive food forming apparatusand the production support means and the food forming drum.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

Another preferred or inventive subject matter of the present inventionis a transport system comprising the movable unit and the productionsupport means.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

The food forming drum is removed from the food forming apparatustogether with the production support means and can be moved to acleaning unit and/or to a storage unit.

Another preferred or inventive subject matter of the present inventionis a cleaning system comprising a cleaning apparatus and the foodforming drum.

The disclosure made to this embodiment of the present invention alsoapplies to the other inventive embodiments of the present invention andvice versa.

Another preferred or inventive subject matter of the present inventionis a storage system comprising a storage unit and the food forming drum.

BRIEF DESCRIPTION OF THE DRAWINGS

The inventions are now disclosed according to FIGS. 1-20 c. Theseexplanations do not limit the scope of protection of the presentinventions. The explanations apply to all embodiments of the presentinvention likewise.

FIG. 1 shows the inventive food forming apparatus.

FIGS. 2A-2N and 2P-2V show different embodiments of the inventive foodforming drum.

FIG. 3 shows another embodiment of a mould drum consistent with theteachings herewith.

FIGS. 4A and 4B shows a different embodiment of a mould drum consistentwith the teachings herewith.

FIGS. 5A and 5B shows a different embodiment of a mould drum consistentwith the teachings herewith.

FIG. 6 shows a different embodiment of a mould drum consistent with theteachings herewith.

FIG. 7A-7G shows a different embodiment of a mould drum consistent withthe teachings herewith.

FIG. 8 shows a different embodiment of a mould drum consistent with theteachings herewith.

FIG. 9A-C shows the production of an insert

FIG. 10 shows the inventive food forming apparatus.

FIG. 11-12 show the movable unit.

FIG. 13 show details of the production support means.

FIG. 14A-14E show the fastening of the drum at the food formingapparatus.

FIG. 15 shows the fixation of the drum at the support- and thedrive-side of the food forming apparatus.

FIG. 16A-B show the fluid control of the food forming apparatus.

FIG. 17 shows the cleaning of the food forming drum.

FIGS. 18A and 18B shows the cleaning of the food forming drum.

FIGS. 19A and 19B shows the cleaning of the food forming drum.

FIG. 20A-20C shows the discharge of the formed product.

DETAILED DESCRIPTION

FIG. 1 shows a layout with a forming apparatus 29, a mass supply system100 for supplying mass to the forming apparatus and a food mass feedmember 101 for distributing the mass to the mould drum 1. A sealingmember is provided which abuts against the surface of the drum aroundfor sealing the surface of the mould drum to prevent leakage of massduring production. Mould drum 1 is provided with product cavities 2. Themould drum comprises at one end a drive side 19 which is connected to amotor means which is preferably located in the forming apparatus. At theopposite side 18, which is in the following called the support side, thedrum is supported at the frame of the forming apparatus.

The drum 1 comprises basically an inner member 77 and at least partiallyporous, inserts. In the present case, the inner member comprises aninner cylinder 75 and a multitude of ribs 76. Two adjacent ribs form inthe present case a recess. The inserts are preferably irreversibly fixedin the recesses of the inner member 77. Regarding preferred fixationtechnologies, reference can be made to WO2012107236 which is herewithincorporated by reference and thus part of the present disclosure.

The mould drum preferably comprises two main parts, an inner member 77,and porous inserts 78. In the present case, the inner member 77comprises an inner cylinder 75, which can be, for example, athick-walled preferably stainless steel tube 75 and one or a multitudeof ribs 76. The ribs 76 and the inner cylinder can be provided as onepart, for example, rotationally casted, or a tube whereby the necessaryrecesses between two ribs 76 are created by machining, preferably bymilling. The inner member can also be a stainless steel tube whereby thenecessary drum design, for example the ribs 76, is already casted or canbe a single-piece sintered part. FIG. 2A shows another embodiment ofinner member 77. The inner cylinder 75 can be for example a thick-walledstainless steel tube which is rotational casted or is a commercialavailable tube whereby ribs are connected to the stainless steel tube byan adhesive connection, for example welding, preferably bylaser-welding.

After connecting the ribs 76 to the tube, this preassembly is preferablypre-machined. The porous inserts 78 are preferably pre-machined as wellbefore both can be fixedly connected to each other for example bybrazing in a vacuum oven. Other bonding means such as glue or stainlesssteel epoxy are also possible. Welding, preferably laser-welding, canalso be used. The inserts will be weld to ribs 76 at the outersurface/diameter of the drum over the whole insert length. Beforewelding other bonding means like glue or stainless steel epoxy can beused too to seal the contact area between insert and rib. The bondingmeans must be approved for use in the food-industry and must beresistant against the force, the pressure, the temperature and/or thechemicals during production and/or during cleaning.

In FIG. 2B yet another embodiment of the present invention is shown.Tube 75, ribs 76 and inserts 78 will all be connected to each other inone set-up, preferably by brazing. This saves considerably in especiallymachining time. In this set-up no machining of the ribs is necessary.Additionally, deformation of the assembly due to welding stresses willbe avoided. Brazing material will be provided between ribs 76 and tube75, and between rib 76 and inserts 78.

Depending on the bonding mechanism which will be used, the pores of theinserts are preferably closed at the bonding locations 73, for exampleto prevent that bonding material will penetrate into the porousmaterial. Even the pores of the surface of the inserts which areprojected on the outer surface of the drum can be closed and/or thepores of both front ends of the inserts. After the adhesion process,preferably brazing, of the ribs 76 to the inner cylinder 75 and/or theadhesion of the inserts 78 to the ribs 76, the mould drum willpreferably be further machined. For instance one or both front ends 3, 4of the drum will preferably be machined and when required and/or not yetdone, the pores of the porous inserts 78 opening out at the drum frontend 3, 4 are preferably closed. This closing can, for example, be doneby deep rolling and/or thermal spraying which will be explained later inthis document.

Distributor means 9, for example to distribute a cleaning liquid to eachpassage 8, are preferably machined into tube 75 and/or porous inserts 78and/or form-fit-means 7, to transfer a torque to the drum are preferablymachined into the tube 75.

FIG. 2C-1 shows an embodiment of manufacturing a drum not by usinginserts but by applying powder directly in the recesses between two ribs76 of inner member 77. After pressing and sintering, a porous structureremains wherein product cavities 2 can be made and/or pores at thesurface can be closed. Depending mainly on the contact surface betweenthe porous material and the ribs, the ribs can be provided with recesses72 a to improve the connection between the porous material and the ribs.

To create passages 8, a filling/insert 68 can be used in every row as aspace-holder to avoid that the powder from which the porous material issintered, enters the space for the passage 8. This filling/insert ispreferably a hard material that can withstand the forces during thepressing of the powder. More preferably, the filling/insert is aparticulate material, that can be removed easily from the passage afterpressing and before sintering these filling/inserts has to be removedwithout damaging the porous structure.

In another embodiment a gas- and/or fluid-permeable structure 72 b isused for creating a passage 8 underneath a porous structure as shown inFIG. 2C-2 till FIG. 2C-4. The permeable structure will support theporous powder before and/or during pressing and/or sintering and/orlater during the subsequent machining of the drum and/or duringproduction of formed articles with the drum. The support structure hasto be gas-, particularly air, and/or fluid-permeable in order to allowair and/or a cleaning fluid to enter and/or exit the porous structure.Preferably, the permeability of the support structure is larger than thepermeability of the porous material. However, preferably, thepermeability is so low that the powder from which the inserts aresintered is held back by the support structure. This permeable supportstructure can for example be made based on a wire mesh which hasbasically a larger permeability than the permeability of the intendedporous structure will have. This is to prevent that air and/or fluid,particularly cleaning fluid will be blocked by the permeable structure.The wire mesh can for example have a wire diameter of 0.4 mm.

The mesh structure will have a permeability of for example 200 micron.In case the chosen permeable structure, for example the wire mesh, isnot rigid enough to withstand the load during pressing of the powder,the permeable structure can be reinforced, preferably by providing alayer with a multitude of layers of permeable structures, which morepreferably are connect them together, for example in a sintering processin an oven. However, the resulting permeable structure should have apermeability still larger than the permeability of the resulting porousstructure.

The passage 8 preferably has a uniform cross section over the entirelength of the drum. Therefore the position of the wire mesh with respectto ribs 76 and with respect to the outer diameter of tube 75 ispreferably uniform as well. FIGS. 2C-3 and 2C-4 shows an embodiment witha means, here a recess 72 c which accommodates the outer end of thepermeable structure, here the wire mesh, so the position of thepermeable structure, here the height, at the location of the ribs issecured. This assures a uniform height of the passage 8. Additionally oralternatively, the permeable structure is connected to the rib by amaterial fit, for example welding. The permeable structure can besupported at another location “M”, here the center of the passagebetween two ribs. This can, for example, be achieved by providing thetube 75 with extensions, preferably over its entire length, for examplemultiple, preferably round, rods connected, for example with their headend, to the outer diameter of tube 75. The wire mesh can be connected tothe extensions by welding or gluing. In a succeeding step the passagearea provided with extensions can be filled with a filler material, forexample a powder material, which filler material is able to withstandthe forces during pressing of the powder from which the porous materialis sintered. After pressing and before sintering the filler materialmust be removed.

When applying the porous material between the permeable structure andouter member 69 of the mold, as will be explained according to FIG. 2H,the used powder can also penetrate into the permeable structure, whichis preferably avoided by choosing an appropriate permeable structurewith openings which are smaller than the average diameter of the powderfrom which the porous structure is made.

During production of formed products, the load on the porous structurewill be at the outer surface of the drum but also from underneath, e.g.from passage 8. The relatively weak porous structure will be deformedand will be kept in place by the connection between the ribs andpermeable structure. The mechanical properties of the permeablestructure can be further increased by material fitting, preferablywelding, the wire mesh against the ribs, preferably over the entirelength of the drum, see 72 d.

In a final step during the production of the drum, the outer diameter ofthe drum assembly will be machined to its final diameter and when notdone yet, the pores at the outer circumference of the drum will beclosed and/or should be kept closed. With this step, for examplegrinding, or with an additional machining step the drum obtains itsfinal diameter.

The pores can be closed, for example by grinding with a suitablegrinding wheel and suitable grinding parameters or it can be done, forexample, by deep rolling. During deep rolling, a rolling element, forexample a sphere, but preferably by a cylinder as a roller, which ispressed against the porous surface to be closed or in case of a drumassembly, against the outer surface, preferably including ribs 76 of thedrum assembly. The compression provided by the roller creates stress inthe surface of the porous material and/or the ribs 76, whereby thisstress will exceed the yield point and a plastic deformation takes placeat the surface layer of the mould drum. The pores of the porous insertswill be closed by this deep rolling. An additional advantage of deeprolling is the increased density in the surface layer, which willincrease the strength and wear resistance in this layer. Duringproduction of formed food products, a sealing member of food mass feedmember 101 is acting under relatively high pressure against the outersurface of the mould drum 1. As a result of the deep rolling, thelifetime of the mould drum will be increased.

Reference can also be made to WO2012/107236 which describes the use of aspraying process, preferably a thermal spraying process to seal theouter surface of the drum. In this process a relatively thin layer willbe applied to the partly porous outer surface which layer will close theporous structure. Afterwards the layer will be machined to achieve thedesired surface roughness, dimensions and tolerances.

The layer doesn't necessarily have to be a metal layer. Another materialcan be used as well as long as the used material is approved for use infood machinery. Further a material should be chosen which has sufficientmechanical properties to withstand the load on the drum and the layershould be wear resistant due to the friction forces on the outer surfaceexerted by the sealing, the cutting member and the processed mass.

The prefabricated drum can be stored. Once there is an order for a drum,the desired product cavities will be machined into the cylindricalsurface of the drum.

FIGS. 2D-2F show another embodiment of the production the porous member70 in situ, here by applying powder, from which the porous member ismade, directly in each recess between two ribs 76 of inner member 77. InFIG. 2D shows a preferred embodiment of the present invention. Here, theribs 76 are provided with recesses 72 a. The overall strength of theconnection between the ribs and porous material will be improved by therecesses in the ribs. The recesses are optional. It is also possible toprovide means which increase the friction between the rib and the porousmember. The shape of the recesses is such that the porous structureform- and/or force-fits in the recesses of the ribs to improve the form-and/or force-fit between the porous member 70 and the ribs. The numberof recesses will depend on the dimension of the porous part and/or theload during production and cleaning of the drum.

For producing the porous layer(s) 70, 71 in-situ, the inner member 77 ispositioned such, that its center axis is preferably in a verticalposition. The porous layer 70 is produced by adding powder to a mold.The mold, for example a cylinder will accommodate the inner member 77but preferably also filling/inserts 68 to provide the passages 8 inevery row. Depending on the binding between the powder and the ribs, thepowder can already be (pre-)pressed and/or (pre-) sintered in order toachieve the porous structure. Subsequently the outside layer 71 will beproduced. The outside layer 71 preferably has a structure with lessporosity, e.g. a denser structure, than the inner layer 70 and ispreferably produced by adding a different powder in a preferablydifferent mold, into which the inner member 77 plus the inner porouslayer 70 are placed. The powder for the outside layer is inserted into agap between the inner member and the inner porous member (s) and themould.

The drum as shown in FIG. 2E can be finished by a sinter process.Afterwards, the cavities are machined into the outer circumference ofthe mould drum, preferably, into both layers 70, 71.

After the sintering process, the diameter of the drum, preferablyexceeds the desired diameter of the drum. Preferably, in a subsequentmachining step, the drum gets its final diameter and/or its final shape.FIG. 2F shows the drum after further machining of the outer diameterwhich can be done after the sintering process but also later on duringthe manufacturing of the drum. The final diameter of the drum isprovided by this machining. Advantage of this embodiment is that a denseouter layer is created with result that there is no need any more toclose the pores at the outer surface of the drum by a machining step orthe like.

FIG. 2G shows a preferred embodiment of the inner member 77.

Mold 72 in FIG. 2H will consist of inner member 77 and filling/inserts68 and will preferably be vertical positioned in a press. The outermember 69 of the cast comprises a cylinder, whose diameter can be,preferably, reversibly decreased. Between two ribs, a filling/insert 68will be provided, to allow space for a passage. After positioning theinner member 77 into the outer member of the mold 69, the gap betweeninner member 77 and outer mold member 69 of the mould will be filledwith powder. Subsequently, the outer member can be reduced in itsdiameter, so that the powder is compressed to produce the porousstructure with interconnecting pores. Heat can be added during thecompression and/or afterwards to achieve a sintered material. Theembodiment in this FIG. 2H is without a dense layer 71 but can, whenrequired, be provided with a dense outer layer.

FIG. 2I shows the compression of the applied powder to create the porousstructure. Arrows showing an inside force which can be applied and canbe, e.g. provided by a pressurized fluid. This inside force preventsthat the inner member will deform due to the press forces at the outercircumference of outer mold member 69. Depending on the stiffness ofinner member 77 and the applied forces at outer mold member 69 theseinside forces will not be necessary. The applied outside force reducesthe outer mould member 69, preferably reversibly, in its diameter andthus compresses the power for the mould member 70. Preferably beforesintering the porous members 70 in an oven, the filling/inserts 68 willbe removed to create passages 8. In another embodiment (not shown) thedrum is sintered as one piece, which is in situ connected to the innermember 77.

Preferably different powders are utilized to produce the outer porousmember 71 and the inner porous member 70 and the production process canconsist out of one or more pressing steps and/or sintering steps.Alternatively, the same powder is utilized for both porous layers 70,71, wherein the material is compressed differently.

In FIG. 2J shows an embodiment with recesses 72 a in rib 76 and recesses74 in porous insert 78. In case the bonding agent is glue (anaerobic,epoxy based, etc) an optimized bond gap is created by the small recessesin 72 a and/or 74. The larger recesses 74, in FIG. 2J, here circularshaped, are used to supply liquid bonding agent to this recess and toall connected recesses. The bonding agent preferably flows from therecess 74 into the slot-like gap 72 a. The bonding agent is supplied,preferably pressed into gap 72 a, 74 after the porous member 78 has beeninserted into between two ribs. After curing this large recess functionsas a form- and/or force- and/or friction-means to prevent that theporous inserts will come loose from the drum during production or thecleaning process.

FIG. 2J can be utilized to explain yet another embodiment of the presentinvention. The fixation of the inserts can further be improved by acombination of mechanical fixation and adhesive means. In a preferredembodiment an adhesive means is provided in the recesses 72 a and 74.Then the inserts will be positioned between two ribs and mechanicallocking means, here a pin (not depicted) will be applied into the largerecess 74, in FIG. 2J the circular shaped recesses and a form-fitconnection will be achieved. In case adhesive means have been added,excess adhesive means can be removed via the small recesses 72 a in thedirection of the outer surface of the drum. The locking pin/lockingmeans are preferably somewhat larger in diameter than the recess 74 inthe inserts and/or rib 76 and by applying the locking pin/locking meansinto this recess, the porous material will deform and a pretensionbetween the porous member and/or the mechanical locking and/or innermember will be achieved.

In another embodiment mechanical fixation in combination with asealant/sealing means can be used. The mechanical fixation will adoptthe forces during production and cleaning and the sealant/sealing meanswill close the small gaps which caused by tolerances during productionof the several parts. Depending on de used sealant only the largerecesses 72 a and 74 for applying the locking pin will be needed and thesmall recesses 72 a and 74 will not be need anymore.”

FIG. 2K shows another embodiment with only small recesses to achieve anoptimized bond gap. In this embodiment a bonding agent has to be appliedto the bond surfaces before assembling the porous inserts in the drum.

To prevent that bonding agent will accumulate in passage 8 in bothembodiments where the porous inserts are in contact with passage 8, nobond gap exists between insert 78 and rib 76. FIGS. 2L-2N and 2P-2Q showa method to produce a drum with an outer member 77 a, which comprises asheet metal tube 71 and porous parts 70. The powder from which theporous parts 70 are produced is placed directly in the recesses betweentwo ribs 76 of outer member 77 a. FIG. 2L shows a subassembly consistingof a thin-walled sheet metal tube 71 and a plurality of ribs 76. Theribs 76 can be provided with a recess and/or a convexity 72 a as forexample shown in FIG. 2D to assure a better bonding and/or a betterform- and/or force-fit between the porous structure and the ribs. In anext manufacturing step, see FIG. 2M, the sheet metal tube and the ribs76 are positioned in a mold 72, preferably in a vertical position, andporous parts 70 are created by adding powder to the mold. The mold willaccommodate the outer member 77 a and an inner member 69 a which ispreferably made of a flexible material. The powder will be added to thehollow space between the cylinders 71, 69 a and the ribs 76. The arrowssymbolize an inside force which can be created for example by apressurized fluid. By pressing mold member 69 a towards the powder, theapplied powder will be compressed and thereafter sintering the porousstructures will be carried out. An outside force (not shown) can preventthat the outer member 77 a will deform during pressing, if needed.

The outer member 77 a will subsequently be connected to the inner member77 by connection means (not shown) for example an adhesive joint, likewelding, soldering, brazing and/or gluing and/or a mechanicalconnection, etc., as depicted in FIG. 2Q. Due to the sheet metal outerlayer 71 there is no need to close the pores at the outer surface of thedrum. The product cavities are later on machined into the outer member,wherein each product cavity extends through the sheet metal layer 71 andinto but not through the porous structure.

Passages 8 are a result of ribs 76 created on inner member 77 as shownin FIG. 2P. Instead of inner member 77, passages 8 can be part of outermember 77 a. Filling/inserts 68 will then be needed to create thosepassages.

FIG. 2R shows another embodiment of manufacturing a drum. The final drumconsists of an inner member and a subassembly of ribs, preferably asupport such as a wire meshes and a porous structure.

In case a wire mesh is used, in a first manufacture step, segments ofwire meshes 72 b are connected, preferably welded to two ribs,respectively, which ribs are positioned preferably in a mold to assurethe correct position of the ribs. In a next step this subassembly ofribs and wire meshes is positioned inside a press. Depending on thedesign of the inner mould member 69 a, filling/inserts 68 can beprovided to allow space for the passages to eject air and/or a cleaningfluid. Subsequently, the gap between the wire meshes and ribs and theouter circumference 69 of the sinter press is filled with sinter-powderand the pressing process can be started. Preferably an individual porouspart is produced between two ribs, respectively, i.e. the poroussintered part is inserted between two ribs 76. After sintering theoutside dimension of the subassembly will, due to shrinkage of thesinter material, be smaller than the outside diameter of the subassemblyafter pressing, i.e. its inner diameter is reduced. In a following stepand according to one embodiment, the subassembly of ribs, preferablywire meshes and the porous structures need to be machined, i.e. itsinner diameter needs to be increased, in order to be able to connect itto the outer diameter of the inner member 77.

The inner member 77 comprises an inner cylinder. The subassembly ispreferably slid over the inner member and both will be connected to eachother rigidly in order to withstand the forces during production andcleaning. This connection can be achieved by using connection meansknown to the person skilled in the art, e.g. bolts but other connectionmeans such as welding and/or a mechanical connection is also possible aslong as the connection meets the hygiene- and/or mechanicalrequirements. By using end caps 3′ and 4′, as for example shown in FIG.4 of this application, the stiffness of the drum can be further improvedby, for example, securing the position of the ribs to recesses in theend caps.

In another embodiment not only the subassembly of ribs and preferably asupport structure such as wire meshes will be positioned in the sinterpress but also the inner member 77. Suitable powder or other material,which creates a material-bond between the ribs and the inner memberwithin the oven and/or during pressing, can be applied between the riband the inner member. During the sinter process not only a connection ofthe porous powder with the ribs and the support structure will occur butalso a connection between the ribs and the inner member.

FIG. 2S shows another embodiment of the inventive mould drum. A singlerib as described in previous embodiments will be replaced by two or moresmaller ones 76, which extend along the outer circumference of the innerdrum an along the entire length of the drum. The smaller ribs are eachbe connected to the inner member, preferably in a flexible manner and/orare flexible in itself so that they can be displaced and/or deformedunder the forces due to shrinkage. In FIG. 2s the ribs are connected tothe inner member 77 by a weld-seam or multiple weld points at position“W” in a direction parallel to the axis of rotation of the drum,preferably before positioning the inner member 77 in the sinter-press.The welding is such that the rib can move, e.g. rotate, in the directionof the porous structure as it will be subjected to forces for exampledue to shrinkage.

During the sintering process the porous structures will adhere to theribs, respectively. FIG. 2T shows the situation after shrinkage. Due tothe bonding between the rib and the porous structure each rib 76 isforced to follow the movement that the porous structure will make duringshrinkage, respectively. The resulting gap between two ribs 76 willpreferably be subsequently closed for example by welding. In case thisgap is relatively large, first filler material can to be added into thegap in order to prevent that shrinkage of the weld will result in abroken bonding of the porous material with the ribs and/or cracks in theweld. The two parts from which one rib is made, are providedmirror-symmetrically, respectively.

From FIG. 2S it can be further seen that after pressing preferably asmall gap is created within the porous structure which extends radiallyfrom the outer circumference of the ribs 76. This can be achieved byremoving a small strip of porous material or by adding a non adheringmaterial above the rib before filling the mold. This gap will preventthat the rib will be stick in its initial position during shrinkage ofthe porous structure. However, in case the porous material is onlyprovided between two ribs and each porous segment is produced separatelyfrom the other segments between two ribs, such a gap is not needed.

FIG. 2U shows yet another embodiment to prevent damage of the connectionbetween the rib and the sintered porous material. Here, the rib 76comprises two parts, which are able to follow the movement of the porousstructure during sintering, particularly during shrinkage of the porousmaterial. Preferably a small gap is created above the rib in order toallow the rib to follow the movement of the porous structure duringshrinkage. Here, each part of the rib has a U-shaped cross section andthe two parts from which one rib is made are providedmirror-symmetrically.

FIG. 2V shows another embodiment of the inventive drum, wherein a singlerib 76 can be used which rib will be connected, for example welded,rigidly to the inner member. Seen from the upper side of the rib, whichis not connected to the inner member, a groove/gap 90 can be applied forexample along the center line, line of symmetry of the rib andpreferably over a certain height, so that the rib is divided into twoparts but has a base 92 into which the groove/gap 90 does not extend.This groove/gap is preferably extending over the entire length of therib. Hence, each rib comprises two smaller flexible segments. Bypreferably providing one or more indentations, e.g. notche(s) 91 in thebase 92 or other parts of the rib 76, the smaller segments are even moreflexible and are particularly able to follow the movement of the porousstructure during shrinkage.

In another not depicted embodiment an insert will be used in the designof the drum. The insert will be manufactured within a sinter mold. Thebottom wall of the mold is preferably provided with a support, forexample a wire mesh, and preferably both sidewalls (extending in thedirection of the axis of the drum) will be provided with sheet metal ora strip, respectively. Then the recess within the mold preferablybetween the wire mesh and the sheet metals or strips will be filled withpowder. After pressing the powder the insert is consisting of a wiremesh, sheet metal and/or strips and the porous structure. In a next stepthe insert will be sintered. Due to shrinkage the outside dimension ofthe insert will decrease in dimension. In a following step the outersidewalls will be machined such that the inserts can be, depending onthe final design of the drum, connected against the inner cylinder ofthe inner member and/or the ribs of the inner member. The machined outersidewalls can also be provided with cams and/or recesses such that theinserts are well positioned with respect to the ribs. Further thesecams/recesses can contribute in holding the inserts in a mechanical wayat their position within the drum. In one of the following steps thepores at the outer surface will be closed

FIG. 3 shows an embodiment of a mould drum 1. Each product cavity 2 isconnected to at least one passage 8 of the mould drum and consists of abottom wall 10 and a sidewall 11. Passage 8 preferably extends fromfirst front end 3 to second front end 4 of the drum. Via the passage 8,gas can be provided to the mould cavities of one row to eject the formedfood product from each cavity and/or the cavities can be vented duringtheir filling. Additionally a cleaning fluid can be pumped into eachchannel 8 in order to clean the channel and/or the cleaning fluid isforced through the porous material into each cavity to clean the mouldcavities. Preferably the drum is provided with conical part(s) 16 and 17at one or both ends 3, 4 for assembling and securing the drum in theforming apparatus as for example depicted in FIG. 1. Protection rims 6are preferably integrated at one or both outer ends 3, 4 of the drum.Each rim 6 protects the outer surface of the drum, particularly theporous material, for example when it is positioned in a storage unit.The rim can be part of the inner cylinder or part of the porous member78. Form-fit-means 7 are preferably provided to rotate the drum in theforming apparatus during production. The drum is provided with a largeinner opening 20, which is in the present case cylindrical. This opening20 preferably extends from the first end 3 to the second end 4.

The distributor 9 is, preferably provided for cleaning purposes and isin the present case a ring shaped groove integrated in at least onefront end 3, 4 of the inner cylinder 75 and the porous inserts 78.Reference is made to WO2012084215. This patent application isincorporated by reference and its disclosure is thus part of thedisclosure of the present application. In WO2012084215 the use of adistributor in the drum is described.

By using an inner member with an inner tube and ribs which extend to theouter surface of the drum together with porous material which ispositioned between two ribs, no air/fluid will leak away to other rowswith product cavities during discharge. This will reduce air consumptionwhich is a main benefit of this design.

FIG. 4A shows yet another embodiment of the mould drum 1 wheredistributor 9 is integrated in the flange part here at second front end4 of the drum. The distributor comprises in the present case amultitude, here three, long hole-shaped openings 9 which extend in thecircumferential direction of a cylindrical part of the flange part ofthe front end. This can be advantageous to provide a high volume ofcleaning fluid through the passages 8 of the drum to assure sufficientcleaning.

Reference can be made to WO2012/107236, FIG. 58 which shows a drumprovided with end caps. In FIG. 4B end caps 3′ and/or 4′ are provided atthe respective front- and rear end of the drum. Form-fit means 7 can bepart of end cap 4′ and in the embodiment according to FIG. 4, therecesses intended as the form-fit-means will also be used as distributor9 for the cleaning fluid in a cleaning apparatus. By using end caps,cover 81 described in this document (see FIG. 11 and FIG. 16a ) will notbe needed anymore which will simplify loading/unloading of the drum inthe forming apparatus. Further, the flexibility is increased regardingthe use of different thickness of the porous structure (thickness canvary approximately between 18 mm and 55 mm depending on the dimension ofthe food product that will be formed). The inlets/outlets for thecleaning fluid 163, here slots in the end caps for fluid flow will,independent from the chosen thickness of the porous structure, open outat the same position at the head end(s) of the drum assembly. Furtherthe inlets/outlets 163 will be designed such that at the opposite sidethey open out in the passage 8 of the drum. The cones 16 (drive side)and 17 (support side) can be part of the end caps and can have the samedimension regardless the thickness of the porous structure.

In FIG. 5A an embodiment with multiple passages 8 a, 8 b and 8 c per row2′ of mould cavities. The porous structure of the porous insert is opentowards these passages. The passages 8 a-c are created by recesses inthe material of the porous inserts. This can be, for example, achievedby machining but preferably the passages are part of the mold duringmanufacturing the inserts. In comparison to the embodiments in FIG. 3and FIG. 4 the embodiment according to FIG. 5A has the advantage thatthe fluid flow, for example pressurized gas and/or a cleaning liquid,can subjected only to one or more but not all passages 8 a-c of one row2′ and thus be directed only to a desired region of each mould cavity inone row 2′ Thereby only a limited volume of fluid flow must be provided.The fluid consumption of the forming apparatus will be reduced. Fluidcan also be directed through all the passages 8 a-c in one row 2′simultaneously and will flow to the bottom wall and sidewall of all theproduct cavities.

Additionally or alternatively at least one support area 14 whichsupports the relatively weak porous insert can be provided. Result isthat the thickness of the porous structure underneath the productcavities can be reduced without risk that this porous structure will bedeformed during operation.

Preferably all formed food products are released from cavity 2-I-IVsubstantially simultaneously. FIG. 5B shows an embodiment with amultitude, here five passages 8 designed for an insert which is providedwith two rows 2′ of cavities. To achieve that the products in twocertain rows 2′ will be discharged in a particular sequence, a selectioncan be made which passage will be provided at what time with fluid, herepressurized gas.

It can be advantageous for discharging formed products to direct thefluid for example first to the bottom and then to the sidewall of theproduct cavity to remove the adhesion forces first between the bottomand then between the sidewall of the formed product and the porousstructure. FIG. 6 shows such an embodiment. The porous structure of theinsert is open towards passages 8 a and 8 c. The porous wall 8 bh ofpassage 8 b is open and the porous walls 8 bv are closed. Closing thepores can be done by machining but can also be done during manufacturingof the inserts by using different powder in the mold. Plate 15 acts as afluid restriction and is preferably a strip with apertures, for examplecircular holes, at each position were a product cavity is located. Theplate 15 is fixedly connected to wall 8 bh for example, by bonding meansand is provided with recesses which are open out to the bottom wall of acavity. By providing channel 8 b first with fluid, for example apressurized gas, it can be achieved that the bottom of product cavitiesin a certain row will firstly provided with fluid. After a certain time,fluid can be provided to channels 8 a and 8 c with result that the sidewall and/or remaining parts of the bottom wall will be provided withfluid to discharge the formed food product out of the cavity. Otherembodiments of directing air to one or more passages simultaneously orwith a time-lag are also possible.

FIG. 7 shows other embodiments of a mould drum 1 which each consist ofan inner tube 75 and relatively large porous members 78, preferably twoor three porous members 78. FIG. 7A shows an assembly which can be usedwhen the drum will be provided with an even number of rows 2′ withproduct cavities 2.I-IV. The drum comprises here only two porous members78. FIG. 7B shows a drum with three porous members 78 which can be usedfor an odd number of rows 2′ with product cavities 2.I-IV. Rib 76, isprovided to create passages 8 and to maintain the porous members 78 in aconcentric position relative to the inner tube 75. Rib 76 b is providedto preferably additionally improve the bonding between the porousmembers. FIG. 7C shows a drum in accordance with FIG. 7A with thedifference that no rib 76 a is provided and that the outer surface isentirely out of a porous material. This is advantageous for closing thepores of the porous material at the outer circumference of the porousmember 787 not by grinding but by deep rolling. When inserts areinterspersed with ribs 76 a, b which are not porous, deep rolling canresult in undefined result e.g. non-round external diameter of the drum.

Shot-peening, preferably controlled by a robot to achieve a uniformsealing of the pores at the outer circumference of the porous member, isa technique which can be used even with ribs.

The inserts of FIG. 7A-C are preferably connected to each other byapplying bonding means to the front ends of the inserts where theinserts are connected to each other.

Depending on the design to discharge formed food products, it can beadvantageous that there is no barrier between two adjacent rows ofcavities with the result that during discharge of a row of food productsfluid, for example air, can flow freely via the porous structure toadjacent rows 2′ of cavities and even into the adjacent passages 8. Theporous structure of the row of cavities which is already emptied can,for example, be cleaned by this fluid and the passage of the row ofcavities which is just filled is already pre-filled with fluid, e.g.air. Depending on the thickness of the porous structure, the openness ofthe porous structure and/or the adhesion between formed product andproduct cavity a fluid flow between adjacent rows of cavities will notresult in undesired discharge of the formed products due to the fluidflow between two adjacent rows 2″ of cavities. An at least partiallyfree flow of fluid can be achieved by positioning the contact surfacesof the porous member not directly above the location of ribs 76, seeFIG. 7D. Same is achieved in FIG. 7E where the porous members 78 areconnected to each other for example by welding, preferably TIG, at theouter diameter and/or at the inner diameter of the porous member.

Between two adjacent rows of cavities in FIG. 7F a rib 76 is provided,respectively, each with a channel 79 or each channel 79 is provided byribs. Each channel can be, preferably separately, connected to a reducedpressure connection, so that cross flow of gas, for example duringdischarge of the formed products in one row by ejecting gas, to anadjacent row of cavities can be at least reduced.

In all the embodiments of FIGS. 7A-F the ribs 76 are preferablyconnected with bonding means to the tube 75 and/or to the porous member78.

FIG. 7G shows, similar to the embodiment according to FIGS. 2-6, anembodiment which can be used in case a flow of fluid between twoadjacent rows of cavities is undesired and results in for example inleakage of air, an excessive air consumption and/or an airflow to a rowof cavities.

A recess 74 in the porous member 78 and/or a rib 76, the recess and/orthe rib may function as a resistance for the airflow from one passage toanother passage.

The drum design depicted in FIG. 7G is advantageous regarding the drumassembly. As shown in FIG. 7G first ribs 76 b will be connected in therecesses of inserts 78, respectively and another set of ribs 76 will bepositioned in recesses in tube 75, respectively. Subsequently, thepre-assemblies can be slid into each other. The ribs 76 b are preferablyprovided with a chamfer.

According to another preferred or inventive design to at least reducethe air flow from one passage to another passage via the porous materialis to impregnate the porous structure between two rows of product with amaterial which is approved for use in the food-industry and which isresistant against circumstances during production and during cleaning(cleaning agents, cleaning temperatures, etc.).

FIG. 8 is showing a different embodiment of a drum which consists of aninner cylinder 75 and relatively small porous members preferably eachrow 2′ with product cavities has a separate porous member 78.

The strength and stiffness of the mould drum is determined by thedimensions of the inner member 77 and by the design of the porousmembers 78. Because of the limited strength and stiffness properties ofporous material it can be necessary to provide support means (not shown)between two adjacent ribs 76.

FIG. 9 shows some embodiments in manufacturing inserts 78.

The Inserts in one of the above mentioned drum embodiments can be madein several ways. First they can be made for example by dividing, forexample sawing, milling or waterjet-cutting segments out of a sinteredporous tube which is manufactured for example by isostatic pressing ofpreferably stainless steel powder. Second the inserts can be made byvertical pressing of stainless steel powder in a pre-shaped mold andafterwards sintering this pre-shaped insert. The inserts, for example,in the drum embodiments in FIG. 7 will preferably be made out of aporous tube and the inserts shown in FIGS. 3, 4 and 8 out of a verticalpressed insert.

In FIG. 9A insert 78 consist of a porous base 70 which is, for example,made from an isostatic pressed tube of porous sintered material with anoutside layer 71 which has a different porosity than the isostaticpressed tube. This outside layer has preferably a dense structure andcan be for example foil, a rolled plate or a thin walled tube,preferably made from stainless steel. This can be advantageous becauseit saves the process to close the pores at the outer circumference ofthe drum. Also possible is that the layer is made by providing differentpowder in the mold which will after pressing and sintering result in aclosed structure. Important is that after the sintering process porousbase 70 will adhere to the outside layer 71.

FIG. 9B shows two embodiments of a drum with inserts 78 whose porousbase 70 are shaped for example by vertical pressing. Each insert isproduced by providing an outside layers 71 as well as an outside layerat both head ends of the insert in the circumferential directionrespectively. The outside layer at both head ends can be utilized asribs and/or to fix the inserts to the inner member 75. A rib preferablyprovides a space between the inner member and the porous insert, whichcan be utilized as a channel for a gas to discharge the product and/orfor a cleaning fluid to clean the porous inserts. Each outside layer canbe, for example, a foil, a plate(s) or made by providing differentpowder in the mold which will after pressing and sintering result in aclosed structure. Important is that after the sintering process porousbase 70 will adhere against outside layers 71. FIG. 9c shows how insertscould be manufactured using a mold 72. At least one preferably alloutside layers of each segment are placed in a mold 72. Afterwards, thepowder of the sintering material is filled into the cavity provided bythe mould 72 and the outside layer(s) 71. Preferably, the powder ispressed and then sintered. During sintering, the sintering powder isadhesively and/or mechanically bonded to the outside layer(s).Subsequently, the insert is fixed to the inner member of the drum,preferably by an adhesive joint and/or by a mechanical bond. In a laststep, the outer surface of the circumferential outer layer can bemachine to achieve the final diameter of the drum. The product cavitiesare preferably machined, preferably milled, into the outer layer as afinal step. Due to the outside layer 71 at the radial circumference ofthe drum, the pores at the outer circumference of each segment need notbe closed.

The embodiments according to FIG. 9 all to prevent that certain surfacesof the inserts are open after the sintering process.

FIGS. 10-19 are showing an embodiment of a movable unit, a formingapparatus, a cleaning apparatus and a storage unit.

As can be seen from FIG. 10 the forming apparatus 29 comprises a driveside 19 and a support side 18 for the mould drum 1 (not depicted). Thedrive side 19 is provided with drive components which rotate the moulddrum during production. The drive side comprises a motor and/or a gearbox that rotate the mould drum 1. At the support side 18, the drum issupported during production against the frame 23.

FIG. 11 shows a movable unit 60 which transports the mould drum forexample from cleaning to production or to a storage unit and vice versa.The movable unit is releasably provided with so called productionsupport means 45. This production support means is explained in furtherdetail according to FIG. 13. In the present case, the production supportmeans is provided with a cover 80 and a mould drum 1 is fixed to theproduction support means 45. The cover 80 will seal and/or supply fluidto the front end 3 of the drum and can be a separate part as shown butit can also be an integrated part of the support structure 51 of theproduction support means 45.

The movable unit 60 in FIG. 12 comprises of a frame 63 and a supportframe 62 to support the production support means 45 and mould drum 1.This support frame 62 is provided with an align mechanism 61 to adjustthe angle of the production support means and mould drum 1 relative tothe forming apparatus, cleaning apparatus and/or storage unit. Heightadjustment 64 will preferably be used to adjust the height of the moulddrum 1 relative to the forming apparatus 29, cleaning apparatus and/orstorage unit. Furthermore, the movable unit preferably comprises anadapter 67 which can, for example rotated by a rotating knob 65. Theadapter 67 can be brought into a from- and/or force-fit connection witha coupling head 57 of the production support means 45 This will be forexample done to secure the mould drum 1 to the drive side 19 of theforming apparatus 29. Furthermore the movable unit is preferablyprovided with positioning means 66 to position the movable unit 60relative to the forming apparatus 29 and/or cleaning apparatus and/orstorage unit. Means can be provided (not shown) to secure the productionsupport means 45 to the movable unit 60.

In FIG. 13 production support means 45 are shown. The production supportmeans support the drum on the movable unit but also at the support side18 of the forming apparatus 29. The production support means are removedfrom the forming apparatus. The production support means comprises,preferably at one of its ends, a support structure 51 with bearings,which are preferably provided in a housing 46. Preferably, the supportstructure is provided with a structure, as depicted in FIG. 13, to alignand/or connect the production support means to the forming apparatus.The production support means further comprises a spindle 52. Spindle nut53 and coupling head 57 are preferably part of spindle 52. The spindle52 is supported at one end in the bearings, which are, in the presentexample provided in the housing 46. By rotating coupling head 57clockwise spindle nut 53 is connected to a driveshaft 21 which is partof the forming apparatus. Thus the spindle 52 and the mould drum 1 willbe secured at drive side 19 of the forming apparatus 29. A support disc54 can provided for additional support and/or guidance of the drum onthe spindle 52. Furthermore, the production support means may compriselocking means 56, to secure the mould drum 1 to the production supportmeans 45. A lever 55 can activate/deactivate the locking means 56. Atension nut 58, which is preferably also part of the production supportmeans, can be utilized to clamp the mould drum at support side 18 and/orat the drive side 19 to the forming apparatus. Further the tension nut58 preferably prevents that spindle 52 and consequently the mould drumcan be removed from the movable unit 60 unintentionally. Means can beprovided to prevent that the tension nut 58 is removed from the spindle.When the drum will be positioned in the cleaning apparatus, theproduction support means preferably remain on the movable unit.

Before picking up the drum from storage unit, preferably a cover 80 isplaced against the first front end 3 of the drum. With the movable unit60, which is already provided with production support means 45, the drumis placed on these production support means, for example, by insertingthe spindle 52 into the inner opening 20 of the mould drum.Subsequently, the drum is preferably secured to the production supportmeans 45 to prevent that it will slide off the means during transport.This can for example be done by turning lever 55 and thus bringinglocking means 56 into a lock position. Cover 81, see also FIG. 11, canbe positioned against second front end 4 of the mould drum. In anotherembodiment, cover 81 can be an integral part of fluid control member 82at the drive side 19 of the forming apparatus 29. Now the movable unit60 can be moved to the forming apparatus 29 and can be positioned in theright position via positioning means 66 and connected to the formingapparatus.

FIG. 14 shows the installation of the mould drum 1 in the formingapparatus 23. In the embodiment according to this figure the productionsupport means 45 are provided with a support structure 51 to alignand/or connect the production support means to the forming apparatus asshown in FIG. 13. In FIG. 14A production support means 45 will slideover one or more pilot pin(s) 24 on the support side 18 of the formingapparatus. In FIG. 14B a cone 17 at the drive side of the drum comes incontact with a cone driveshaft 22. Form-fit-means 7 of the mould drum 1have to correspond with the corresponding form-fit-means in thedriveshaft 21. In case the form-fit-means are designed differently, forexample with different cams as in FIG. 3 and FIG. 4 the drum will fitonly in one single angular position relative to the driveshaft 21 of theforming apparatus. According to another, not depicted embodiment,instead by form-fit-means 7 the drum is driven by friction-force betweenthe cones 17 and 22. Loading the drum into the forming apparatus is thussimplified. Preferably cone 17 is made from stainless steel and cone 22from another material like brass to prevent galling. It is even possibleto position cone 17 at the outer circumference of the drum to createmore friction and it will ease the loading of the drum in the formingapparatus while you view cone 17 moving into cone 22. Theretofore thedesign as shown in FIG. 14 needs to be redesigned. FIG. 14C shows themould drum 1 in a manually set position, here with a small gap betweencone 17 of drum 1 and cone 22 of driveshaft 21. Tension nut 58 is in areversed position on spindle 52. FIG. 14D shows that via rotating knob65 clockwise, adapter 67 and coupling head 57, the spindle nut 53 willbe tightened on threaded part 25 of driveshaft 21.

During this tightening, the driveshaft 21 remains in a standstillposition. Depending on the necessary torque to tighten or loosenthreaded part 25, the gear ratio of the gearbox can be sufficient toprevent that driveshaft 21 will rotate. When the gear ratio is not highenough, rotation of the drive shaft can be prevented by using a drivemotor provided with braking means or other mechanical means.

FIG. 14E shows the final step in securing the mould drum 1 to theforming apparatus 29. Tension nut 58 will be rotated here clockwise,preferably by a torque wrench with a preset value, in order to removethe clearance between the cones 17, 22 and apply pre-tension betweencone 17 of the drum and cone 22 of the driveshaft at the drive side 19of the forming apparatus 29 and further between cone 16 of the drum andcone 59 of bearing house 46, which is part of production means 45, atthe support side 18 of the forming apparatus 29. Drum 1 is in its finalposition and the drum is now clamped and secured to drive side 19 andalso clamped and secured to support side 18 of the forming apparatus 29.

This step can be done while the movable unit is still connected to theproduction means as shown in FIG. 14E but due to the limitedaccessibility of the tension nut 58, it is preferable to move first themovable unit away from the forming apparatus, preferably by removing theconnection (not shown) between production support means 45 and movableunit 60.

In an alternative embodiment spindle 52 and tension nut 58 are fixed toeach other or are made as one part. By rotating coupling head 57clockwise spindle 52 and tension nut 58 will rotate till the clearancebetween the cones 17, 22, 16, 59 is removed and pre-tension betweencones 17 and 22 and cones 16 and 59 is applied.

In an embodiment where the production means are not provided with asupport structure 51 to align and/or connect the production means to theforming apparatus the drum can be clamped and secured to the supportside 18 of the forming apparatus by connecting/clamping the bearing toframe 23 of the forming apparatus.

In another preferred embodiment the drum will not be clamped manually tothe forming apparatus but by, preferably pneumatic driven, actuators. Inthis embodiment the actuators are connected to a rod which can be drivenin axial direction of the drum. This rod and spindle 52 are able to hookinto each other. As soon as the drum is loaded in the forming apparatusand the rod is hooked to the spindle, the actuators will be activatedand will pull the rod and thus the spindle and hence the clearancebetween cones 17 and 22 and cones 16 and 59 will be removed. By applyingthe desired force to the actuators the drum will be clamped and securedsufficiently to the forming apparatus. Unloading the drum can be done inthe opposite way.

During the forming process especially the sealing member will cause highmechanical forces on the outer surface of the drum. Components whichhave to absorb these forces will have large dimensions and will berelatively heavy. By connecting the sealing member directly with thebearings of the drum a so called force-closed system will be createdwhich will result in smaller and lighter components.

The forming apparatus may only be started when a drum is positioned andis secured in such a way that it cannot get loose from driveshaft 21 atthe drive side 19 and production means 45 at the support side 18, forexample by a suitable choice of the dimensions of the cones 16, 17, 22,59 and form-fit-means 7. Even when even spindle 52 and tension nut 58are not fully tightened or will be lost during operation of the formingapparatus the drum shall preferably not fall out of position. Coverspreferably prevent unsafe situations and can only be closed when themould drum is secured in the forming apparatus and (or the productionsupport means 45 are secured to the forming apparatus. Only closedcovers can activate sensors whereby the forming apparatus can bestarted.

In FIG. 15 the production support means 45 and drive means for the drumare shown. At drive side 19 the driveshaft 21 is driven by a drive motor34 and preferably a gearbox 35. The gearbox 35 is here provided with ahollow shaft 31 and driveshaft 21 is supported in bearings 33 preferablylocated in a bearing houses 32 more preferably on each side of thegearbox (not shown). At the support side 18 of the forming apparatus 29the mould drum is beared by bearing 47, which is preferably assembled inbearing house 46, and is part of production support means 45. One of therequirements for the bearings is to withstand the acting forces duringoperation and to be suitable for the use in a forming apparatus. Theembodiment of the bearing houses including bearings, lubrication,assembling/disassembling of the bearings, sealing means and overalldesign of the bearing houses is a preferred embodiment and not limitedto the embodiment shown in this figure.

FIG. 16A shows an embodiment of the fluid control from the formingapparatus 29 to and/or from the drum 1. The fluid is preferably a gas,more preferably a pressurized gas. The cover 80 at support side 18 willclose passages 8 and will rotate together with the drum. This coverprevents also that the fluid will flow from one passage to anotherpassage. In case cover 81 is a separate part as shown in FIG. 16, thiscover must be connected to the drum at drive side 19 before the drumwill be positioned in the forming apparatus 29. The cover 81 will rotatetogether with the drum and is used to reduce the dimensions of thepassages in the drum to smaller openings to prevent that fluid willenter in more than one passage simultaneously. The number of channels inthe cover 81 is preferably in accordance with the number of rows 2′ ofcavities in the mould drum 1.

FIG. 16B shows a fluid control member 82 which comprises several partsand can be secured at the drive side 19 of the forming apparatus viafastening means for example a bayonet connection 84 in ring element 83.Other main parts are contact ring 85, spring element 86, counter ring87, adjusting rod 88. Adjusting rod 88 is an option and can be used tochange the discharge position manually. The discharge position is mainlydetermined by the size and/or shape of the formed products. Preferablythe discharge position can be changed via valves to achieve thatsucceeding rows of discharged products are each with equal distance onthe outfeed conveyor the starting moment of the air (fluid) supply to apassage is crucial and this starting moment should be the same at everysucceeding row. When changing the speed of the drum this starting momentof air supply in relation to the position of the row of cavities in thedrum to be discharged has to be changed too due to the inertia ofpressure build up in the passage. Changing this starting moment can bedone manually via an Operating Panel but preferably it will be anautomatic adjustment related to the speed of the drum. When the speed ofthe drum increases the starting moment of air supply must occur earlier.

The air supply requires preferably a fast operating valve. Beside thestarting moment the valve should preferably delivers in every succeedingrow approximately the same amount of air to prevent that formed productswill be discharged differently at every succeeding row to prevent thatthe formed products are not positioned properly in one line on theoutfeed conveyor. Additionally a fast closing of the valve will resultin less air consumption during production. and/or via a fluid controlmember which will be driven according settings in an operating panel.Contact ring 85 is in direct contact with cover 81 and is provided withrecesses and channels to control the fluid to the drum. Spring element86, for example air bellows, cylinders, compression springs, etc., willkeep contact ring 85 in direct contact with cover 81 to prevent leakageof fluid. The friction between contact ring 85 and cover 81 must be keptas low as possible to prevent that these parts will wear too quickly.This can in a more preferred embodiment be achieved by a smaller contactring 85 which has only a limited contact surface with cover 81.

In FIG. 17 shows cleaning apparatus 140 which is provided with a hood160 which can be opened for loading/unloading the mould drum and will beclosed during the cleaning process. The hood can be provided withwindow(s) to inspect the cleaning process. With the movable unit 60,which is provided with production support means 45 and with a mould drum1, the mould drum is loaded at load side 141 into cleaning apparatus140. The mould drum is placed into the cleaning apparatus without theproduction support means. The mould drum can be disconnected from theproduction support means by lever 55 which will deactivate locking means56. After the drum has been positioned in cleaning apparatus 140 themovable unit with the production support means will be removed. Theproduction support means 45 will remain on the movable unit and can forexample be used to pick another drum out of the storage unit and loadthis mould drum into forming apparatus 29. When during production offood products the cleaning process of the drum in the cleaning apparatusis finished and production support means 45 are still used in theforming apparatus, this cleaned drum can be unload from the cleaningapparatus by the movable unit together with a second availableproduction support means or with simplified means without built-inbearings.

Cleaning apparatus 140 can be provided with a heating element forheating the fluids used during the cleaning process. In most casesfactories have already hot water taps whereby a temperature controlvalve satisfies and a heating element is not necessary anymore whichresult in lower costs for the cleaning unit.

To prevent that drum 1 will not be cleaned according the prescribedcleaning process as a result of a lack of cleaning agents, thereservoirs for cleaning agents is preferably provided with leveldetection. When the cleaning agent levels are too low the cleaningapparatus will not start and this will be showed by an operating paneland/or a signal lamp.

FIGS. 18A and 18B showing a first embodiment of cleaning apparatus.After the drum has been placed into its position in the cleaningapparatus, the cover- and/or fastening means 143 is moved towards thedrum, until it is in contact with the respective front end. Withfastening means the cover can be secured to the drum. At their contactside with the drum, cover means 143 preferably comprises outside sealingmeans 144. The cover is preferably further provided with a disc which isprovided with inside sealing means 145. Both sealing means preferablyensure that the cleaning fluid will be directed to discharge opening146. At the distributor side 142 cover means 150 is provided. Bothoutside sealing means 151 and inside sealing means 152 preferablyprevent that cleaning fluid will not be directed to the passages 8 ofthe mould drum to be cleaned.

FIG. 18B shows one or more fluid channel(s) 153, which are integrated incover means 150 and which direct the cleaning fluid to the ring shapeddistributor 9 of the drum and from there into passages 8. The amount ofcleaning liquid that can be provided depends mainly on the dimension ofchannel 153, the dimension of the distributor, the dimension of thepassages in the drum and the porosity of the inserts and the size of thepump.

By designing the form-fit means 7, 12 in a way that the mould drum 1will fit only in one single rotational position to the cleaningapparatus the channels 53 which open out in the distributor of the drumcan be relatively large.

Reference is made to WO2012084215 which is herewith incorporated byreference and is thus part of the present disclosure, describes apreferred cleaning process. During cleaning the mould drum isstandstill, i.e. does not rotate and a spray means 161 with a multitudeof nozzles rotates via drive means 162 around the drum and is connectedto fluid supply channel 156. The run time of the nozzles, the rotationspeed of the nozzles and the cleaning fluid to be used can be standardvalues or can, for example, be chosen depending on the contamination ofthe drum. In order to clean the passages 8 of the mould drum, dischargeopening 146 must be open.

When the porous product cavities 2 have to be cleaned the dischargeopening 146 must be closed. Therefore the discharge opening is inconnection with a valve (not shown) which will be operated via, forexample, a PLC in order to automate the cleaning process.

Fluid supply 157 is preferably directing cleaning fluid to fluid channel155 and from thereon to the inner opening 20 of the mould drum. Cleaningthe inner opening of the drum is an option and can be done either byfilling the inner opening with cleaning fluid and let the cleaning fluidwork for a certain time. When cover 143 is provided with drive means itis also possible to make use of a continuous flow of cleaning fluidwhich can be controlled by opening and/or closing cover 143.

FIGS. 19A and 19B show a second embodiment of cleaning apparatus 140 andis based on the drum described in FIG. 4. Difference with FIG. 18 isthat distributor 9 of the drum is integrated in the flange part atsecond front end 4 of the drum. Due to the design of the distributor ahigher volume of cleaning liquid can be circulated in this embodiment.The person skilled in the art understands, that the cleaning fluid ispreferably recycled during the cleaning process and that the fluid pathmay comprise a filter to filter particles out of the cleaning fluid. Thecleaning fluid is preferably water. This water can be heated by a heaterand/or a chemical substance can be added depending on the contaminationof the mould drum. After cleaning of one or more mould drums, thecleaning fluid is preferably, at least partially renewed.

In a third embodiment of cleaning apparatus 140 cover means 150 will beprovided without fluid stop 158. The inner opening of the drum can nowbe cleaned by filling the inner opening with cleaning liquid and let thecleaning fluid soak for a certain time. When cover 143 is provided withdrive means it is also possible to make use of a continuous flow offluid which can be controlled by opening and/or closing cover 143.

FIG. 20 shows several embodiments of discharging formed food productsfrom the cavities. As depicted in FIG. 20A during rotation of the moulddrum, for example a mould drum according to FIG. 7F a gas, herecompressed air, will be provided, see arrow P, to passage 8 of the rowof cavities which is in the discharge position. The gas will flow viathe porous structure also to the adjacent rows of cavities see arrowsFF. In FIG. 20B channel 79 a is connected to a region with a relativelylow pressure for example the ambient pressure but preferably a reducedpressure (vacuum)-connection see arrow V. The reduced pressure inchannel 79 a will prevent that fluid will flow from channel 8 a to theadjacent channel 8 b and will prevent a flow of fluid through the porousstructure to the product cavities in row 8 b by removing fluid which iswithin the porous structure, see arrow FFb. In this embodiment fluidwill still flow to channel 8 c, see arrow FFc, this can be prevented byconnecting channel 79 b also to a region with relatively low pressure.FIG. 20C shows a mould drum, preferably the mould drum according to FIG.7A-E, where passage 8 b is connected to a region with a relatively lowpressure to remove the fluid which is within the porous structure. If afluid flow to the porous structure in row 8 c is undesired, this passagecan also be connected to a region with low pressure.

The drum preferably comprise identification means (reference sign 12 inFIGS. 3 and 4), the forming apparatus can comprise recognition means(reference sign 13 in FIG. 14A), the cleaning apparatus can compriserecognition means (reference 13 in FIG. 18B and FIG. 19B) and preferablythe storage unit too.

In FIG. 3 and FIG. 4 the form-fit means 7 are designed as a multitude,here three cams wherein at least one cam is different in size and/orshape with the result that the drum will fit only in one rotationalposition in the forming apparatus and/or cleaning apparatus. Especiallyin the forming apparatus it can be preferable to stop the rotation ofthe drum always in the same position of the drum. The exact knowledge ofthe rotational position of the mould drum in the forming apparatus canbe utilized to control the filling- and/or discharge process of theforming apparatus.

Identification means 12, preferably an RFID, will be positionedpreferably in one cam of form-fit-means 7. As a result, it is possibleto recognize which drum is during what timeframe connected to theforming apparatus. During production the exact position of the drum isknown and during production as well as during cleaning, a screen with apre-programmed menu can automatically pop-up and production parametersand cleaning parameters (process parameters, what cleaning fluids areused during what timeframe) can be logged. In a simplified version,instead of identification means 12 the drum can be provided with a cam.The forming apparatus can be provided with a sensor instead ofrecognition means 13. During production the exact position of the drumis known. The menu for the drum to be used must be selected manually.Production and cleaning parameters can be logged.

When positioning a drum with a simplified ID as for example, an engravedunique number in the forming apparatus the customer put this ID numbermanually in the operating panel and a menu which contains the operatingparameters pops up.

When the drum is positioned in the cleaning apparatus the menu whichcontains the cleaning parameters and/or the prescribed cleaningprocedure pops up after putting the drum's ID manually in the operatingpanel.

In a preferred embodiment without recognition means in the formingapparatus and cleaning apparatus the drum can be provided with a RFIDtag which tag is provided with a memory for storing information on it.When the drum is positioned in the forming apparatus the information onthe tag can be read, for example by manual operation into the operatingpanel/control unit. This information can contain a menu/recipe withoperating parameters and/or it contains also information about previousruns of the forming apparatus. After production with the formingapparatus information which was read but also information about thefinished production run can be sent and stored automatically on thememory of the tag.

When the drum will be cleaned in the cleaning apparatus the informationon the tag can be read, for example by manual operation into theoperating panel/control unit, which information can contain amenu/recipe with cleaning parameters and/or the prescribed cleaningprocedure for this particular drum and/or information about previouscleaning actions. After cleaning the information which was read but alsoinformation about the finished cleaning action can be sent and storedautomatically on the memory of the tag.

In this way the customer can always check the history of production runsand/or the history of cleaning actions and can check if a particulardrum is cleaned according the prescribed cleaning procedures (dates andtimes, process, used cleaning fluids).

In all above mentioned embodiments the production menu and/or productionhistory can be stored in the memory of the forming apparatus and thecleaning menu and/or prescribed cleaning procedure and/or cleaninghistory and/or volume used cleaning fluids can be stored in the memoryof the cleaning apparatus but this is not preferable.

LIST OF REFERENCE SIGNS

-   1 mould drum-   2-I-V product cavities-   2′ row of cavities-   3 first front end (left side)-   3′ end cap at front end 3-   4 second front end (right side)-   4′ end cap at front end 4-   6 protection rim-   7 form-fit-means-   8 passage-   9 distributor-   10 bottom wall-   11 sidewalls-   12 identification means-   13 recognition means-   14 support area insert-   15 fluid restriction-   16 truncated cone (support side)-   17 truncated cone (drive side)-   18 support side forming apparatus-   19 drive side forming apparatus-   20 inner opening drum-   21 driveshaft forming apparatus-   22 cone driveshaft forming apparatus-   23 frame/frame member forming apparatus-   24 pilot pin forming apparatus-   25 threaded part driveshaft-   29 forming apparatus-   31 hollow shaft within gearbox-   32 bearing house (drive side)-   33 bearing (drive side)-   34 drive motor-   35 gearbox-   45 production support means-   46 bearing house (support side)-   47 bearing (support side)-   51 support structure-   52 spindle-   53 spindle nut (part of spindle 52)-   54 support disc-   55 lever-   56 locking means-   57 coupling head (part of spindle 52)-   58 tension nut-   59 cone bearing house-   60 movable unit-   61 align mechanism-   62 support frame-   63 frame movable unit-   64 height adjustment-   65 knob-   66 positioning means-   67 adapter-   68 filling, insert-   69 outer member mold, outer circumference of the sinter press-   69 a inner mould member-   70 porous base, porous layer, porous member-   71 layer-   72 mold-   72 a form fit means, recess in rib 76-   72 b permeable support structure-   72 c recess in rib 76 to accommodate wire mesh-   72 d weld to connect wire mesh against rib-   73 bonding location-   74 recess in porous inserts 78-   75 inner cylinder, tube-   76 rib-   77 inner member-   77 a outer member-   78 (partially) porous insert, (partially) porous segment,    (partially) porous member-   79 channel-   80 cover support side-   81 cover drive side-   82 fluid control member-   83 ring element-   84 bayonet connection-   85 contact ring-   86 spring element-   87 counter ring-   88 adjusting rod-   90 gap, groove-   91 indentation, notch-   92 base-   100 mass supply system-   101 food mass feed member-   140 cleaning apparatus-   141 load side cleaning apparatus-   142 distributor side cleaning apparatus-   143 cover-means, fastening-means-   144 outside sealing means for cover-means 143-   145 inside sealing means for cover-means 143-   146 discharge opening-   150 cover means-   151 outside sealing means for cover-means 150-   152 inside sealing means for cover-means 150-   153 fluid channel to distributor-   155 fluid channel to inner opening drum-   156 fluid supply spray means-   157 fluid supply inner opening drum-   158 fluid stop-   160 hood-   161 spray means-   162 drive-means for spray means 161-   163 inlet for the discharge fluid and/or cleaning fluid, slot

The invention claimed is:
 1. A food forming drum comprising: a multitudeof rows of product cavities, each of the multitude of rows comprisingone or a multitude of product cavities, wherein the one or multitude ofproduct cavities are provided as one or more at least partially porousmembers made from a porous material with interconnecting pores, whichare beared rotationally at a forming apparatus, and wherein the foodforming drum comprises a truncated cone at least at one of its frontends.
 2. The food forming drum according to claim 1, wherein the one ormore at least partially porous members are directly or indirectlyconnected to an inner cylinder at at least one bonding location, whereinthe pores at a surface of the one or more at least partially porousmembers, in the bonding location are at least partially closed.
 3. Thefood forming drum according to claim 1, wherein the pores at a surfaceof the one or more at least partially porous members adjacent to atleast one of the front ends of the food forming drum are at leastpartially closed.
 4. The food forming drum according to claim 1, whereinthe food forming drum comprises an inner cylinder and at least one ribbetween the inner cylinder and the one or more at least partially porousmembers, wherein the at least one rib is connected to the inner cylinderby a form- and/or force-fit or by an adhesive bond.
 5. The food formingdrum according to claim 1, wherein the food forming drum comprises atleast two form-fit-means to rotate the food forming drum.
 6. The foodforming drum according to claim 5, wherein a shape of one of theform-fit-means is different than a shape of another one of the form-fitmeans.
 7. The food forming drum according to claim 1, wherein the one ormore at least partially porous members are directly or indirectlyconnected to an inner member at at least one connecting region, that ismade by an adhesive connection and/or by form- and/or force- and/orfriction-fit-means.
 8. The food forming drum according to claim 7,wherein the form- and/or force- and/or friction-fit-means extend throughan entire axial length of the food forming drum.
 9. The food formingdrum according to claim 7, wherein each of the one or more at leastpartially porous members is fixed by two or more form- and/or force-and/or friction-fit-means.
 10. The food forming drum according to claim1, wherein the food forming drum comprises end caps, and wherein the endcaps comprise form-fit-means and/or friction-means to rotate the foodforming drum and/or an inlet and/or outlet for a discharge fluid and/orcleaning fluid.
 11. A food forming apparatus comprising: the foodforming drum according to claim 1, and a cone that is configured tocooperate with the truncated cone at the front ends of the food formingdrum.
 12. The food forming apparatus according to claim 11, wherein thecone at the apparatus is part of a drive shaft.